eco kiln pilot plant project brief(vsbk), has been developed2. this technology has significant...
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ECO - KILN
PILOT PLANT
PROJECT BRIEF
TABLE OF CONTENTS
Project Brief
BACKGROUND 2
THE PILOT PLANT 2
WAY FORWARD 3
TECHNICAL DETAILS OF PILOT PLANT 3
PROJECT PICTURES 4
Annexures 5
ANNEX 1 MATRIX OF DECISIONS FOR BRICK MAKING TECHNOLOGIES 6
ANNEX 2 OVERVIEW OF WALL BUILDING MATERIALS + COSTS IN MALAWI 7
ANNEX 3 COMPARISON BETWEEN TRADITIONAL CLAMP AND ECO-KILN TECHNOLOGY 8
2
BACKGROUND
The growing population, especially in the urban areas and migration in Malawi has
put pressure on the construction industry to develop adequate housing and infrastructure to meet the demands of this growth. UN DESA (2012) projections suggest that, by 2025, almost 19% of Malawi’s population will be urbanized. This
figure is expected to rise to about 32% by 2050. Currently, UN- Habitat (2010) estimates that demand for housing in Malawian main urban centres alone is 21,000 units per year over the next decade. This does not take into account the materials
need from public and commercial infrastructure and housing demands in rural areas.
If an average of 85,000 burnt bricks is required to construct a typical urban house
usually brick-fenced, approximately 1.7 billion burnt bricks are needed each year to meet the current urban housing demand.
The main building material that is used in Malawi in both rural and urban settings for all building types is burnt bricks. The 2008 Population and Housing Census shows
that burnt bricks (38.5%) are dominant walling materials in the country, followed by adobes and mud. In the last two decades, there has been a significant shift from mud walls mostly to burnt bricks. This shift has not only been seen in urban areas,
but rural population increasingly prefers burnt bricks as well. This has resulted in a shift from about 10% to almost 40% during the last decade. Concrete and other cement-based products account for only 0.6% of all walling materials in all
probability due to the high costs of these materials. Thus burnt bricks are and will be the dominant building materials in Malawi both in urban and rural settings.
Traditionally bricks used for construction in Malawi are produced by baking moulded clay, with fuelwood as the primary fuel in extremely inefficient kilns. The majority of the fuelwood used for firing is not harvested sustainably, thus increasing
pressure on Malawi’s natural resources. The brick production sector is largely informal with little long-term investment in technology or in skill development, which compromises the quality of bricks produced.
THE PILOT PLANT
In an effort to address the challenges of improving the brick industry in Malawi, CCODE1 undertook a study on the energy efficient and environmental friendly
methods of brick production. The study found out that in Asia an-energy efficient and environmental friendly brick firing method called Vertical Shaft Brick Kiln (VSBK), has been developed2. This technology has significant advantages over the
traditional and Malawi's predominantly used– clamp technology. Thus CCODE after having carried out a feasibility study in 20123 and a baseline study4 in 2013 ventured in the creation of the enterprise Eco-Matters Ltd and the construction of a
VSBK pilot plant colloquially called Eco-Kiln.
Supported by GIZ5, DFID6 and TARA7 the construction of the plant was finished in
early 2015 and Eco-Matter Ltd took up regular production in April 2015. Meanwhile
1 CCODE, Centre for Community Organisation and Development, a Malawian NGO with focus on low
cost housing and slum up-grading founded in 2003 (www.ccodemw.org) 2 Urs Heierli, Brick by Brick: The Herculean Task of Cleaning up the Asian Brick Industry 3 Maity, S. & Nagrath, K. (2012): MALAWI, Feasibility of VSBK Technology for cleaner brick production 4 Clíoma (2013): Brick Production Provisional Baseline Study 5 Deutsche Gesellschaft für Internationale Zusammenarbeit GmbH (GIZ) is a non-profit company
specialized in international development. It is owned by the German Federal Government 6 Department for International Development (DfID) is a United Kingdom government department
responsible for administering overseas aid 7 TARA, Society for Technology & Action for Rural Advancement is a social enterprise set up in
1985 at New Delhi, India
3
the Eco-Kiln established by Eco-Matters has established itself as being one of Africa’s most energy efficient brick firing technology.
WAY FORWARD
After the successful demonstration of the Eco-Kiln technology the project now intends to disseminate the technology through commercial mode, anchoring the required
knowhow at Eco-Matters which will make it available to interested entrepreneurs.
With the dissemination of the Eco-Kiln technology in Malawi Eco-Matters and its partners pursue the following goals:
Increase the availability of affordable, high quality, environmental friendly building material to the Malawian public
Creation of more than 1,000 small to medium scale enterprises in the SME
sector and ancillary industries
Creation of more than 20,000 sustainable “GREEN JOBS” thereby helping in reducing poverty
Saving of 850,000 tonnes of fuelwood annually
Saving of 1,500,000 tonnes of CO2 annually
Use of more than 90,000 tonnes of agricultural and industrial waste (e.g.
leftovers of tobacco industry, ground nut production, boiler ash and duff coal) supporting the Malawi’s contribution towards promoting resource efficiencies and contributing to Global Sustainable Development Goals.
Recurring use of 50,000 tons of coal creating a business of USD 10 million
within the country thereby promoting inclusive growth.
Reducing the embodied energy in housing, thereby pioneering the path of energy saving in Africa
In August 2016 Eco-Matters supported by GIZ and TARA started information
sessions all over Malawi. Till date several entrepreneurs have shown keen interest and several consultations are currently going on in preparation for the setting up of more Eco-Kilns.
TECHNICAL DETAILS OF ECO-KILN PILOT PLANT
4 shaft VSBK
Level of loading platform at 7.50 m
Expected daily output 20,000 bricks
Expected annual output 6,000,000 bricks
Number staff 160 - 180
Saving of fuelwood per year 3,000t
(This corresponds to the dry weight of all the trees standing in an area of 400 x 400m of a fully grown forest)
Saving of CO2 emissions per year 4,080t
6
ANNEX 1
MATRIX OF DECISIONS FOR BRICK MAKING TECHNOLOGIES (ACCORDING TO MALAWIAN CONTEXT)
Wood fired
clamp
Coal fired clamp
Improved clamp
Scoved kiln
MK Kiln Up draught
kiln
Down draught
kiln
ZigZag kiln
Habla kiln
BTK Hoffmann kiln
VSBK Tunnel kiln
Roller hearth
Malawian Bench mark
Capable to produce
Roofing tiles Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes No Yes Yes NA
Hollow bricks Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes
Solid bricks Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes
Floor tiles Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes No Yes Yes NA
Capacity of kiln Moderate Moderate Moderate Moderate Moderate High High High High High High Variable High High Low-Variable
Type of fuel Variable Variable Variable Variable Variable Variable Variable Variable Fixed Variable Variable Fixed Variable Variable Fixed
Fuel switch facility Yes Yes Yes Yes Yes Yes Yes No No Yes Yes No Yes Yes No
Homogeneity of temperature Low Moderate Moderate Moderate Low High High High High High High High High High High
Energy requirement /kg brick High High High High High Moderate Moderate Moderate Moderate High Moderate Very low High High Low - Very Low
Heat recovery for drying No No No No Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes
Emissions to atmosphere High High Moderate High Low Moderate Moderate Moderate Moderate Moderate Moderate Low Moderate Moderate Low
Workplace emissions High High High High Moderate Moderate Moderate Moderate Moderate Moderate Moderate Low Low Low Low
Possibility of fulfilling emission norms
Low Low Low Low Low Moderate Moderate Moderate High Moderate High High High High High
Required green brick quality Low Low Low Low Low Low Low Low Low Low Low High Low Low High
Product quality Low Low Low Low Medium Good Good Good Good Good Good Good Good Good Good
Monthly production Low Low Low Low Low High High High High High High Variable Very high Very high Low – Fair
Land requirement Low Low Low Low Low High High High High High High Low High High Low
Ability to operate throughout the year
No No No No No Yes Yes Yes No No Yes Yes Yes Yes Yes
Production losses High High High High Moderate Low Low Low Low Low Low Low Low Low Low
Investment Low Low Low Low Low Medium Medium Medium Medium Medium Very high Medium Very high Very high Low – medium
Return on investment Fast Fast Fast Fast Fast Medium Medium Medium Medium Medium Medium Medium Slow Slow Fast
Organisational requirements Low Low Low Low High High High High High High High High High High High
Availability of replicas Easy Easy Easy Easy Difficult Difficult Difficult Difficult Difficult Difficult Difficult Difficult Difficult Difficult Easy
Local capacities for construction
Yes Yes Yes Yes No No No No No No No No No No Yes
Local availability of materials for construction
Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes No No Yes
Experience of implementation Yes Yes Yes Yes No No No No No No No No No No Yes
Valid CDM-PDD No No No No No No No No No No No Yes No No Yes
Total positive points 7 7 7 7 9 8 8 9 10 7 8 19 8 8
7
ANNEX 2
OVERVIEW OF WALL BUILDING MATERIALS + COSTS IN MALAWI
(As of Mai 2013)
Load bearing wall < 3.50 m; Plastered on one site
Material Average cost [MK]
Unit size
[mm]
Wall thickness [mm]
Remarks
Per unit Per m² wall L x W x H
Traditional burnt
brick
4.50 3,840 L 170 – 230
W 80 – 105
H 40 – 90
(see8)
170 - 230 High breakage rate
Un-uniform size and shape leads to high mortar and plaster needs Un-reliable compressive strength
Eco-Kiln brick 22.50 4,270 230 x 110 x 75 230
Eco-Kiln brick New type
51.50 2,930 230 x 190 x 95 190
Stabilised Soil Block
73.50 6,500 290 x 140 x 90 290
Interlocking Bricks
144.00 6,240 230 x 220 x 115 220
Not loadbearing according to standards, but partly used as loadbearing wall in Malawi
Hollow Concrete
Block
310.00 4,310 450 x 150 x 200 150 Requires plastering on both sides
(considered in costs)
Stabilised Soil
Block
73.50 3,700 290 x 140 x 90 140
8 Clíoma (2013): Brick Production Provisional Baseline Study
8
ANNEX 3
COMPARISON BETWEEN TRADITIONAL CLAMP AND ECO-KILN
Traditional Clamp Eco-Kiln
Energy consumption [MJ/kg brick] 4.5 – 7.0 0.7 – 0.9
Emissions (SPM [mg/m³]) ~ 1,900 ~ 150
Emissions (CO2 [kg/1000 brick]) ~ 900 ~ 280
Breakage 15 – 20% < 5%
Homogeneity of temperature Low High
Heat recovery for drying No Yes
Workplace emissions High Low
Product quality Low High
Production season During dry season All year round
Possible Fuels Wood logs Coal peas or large pieces (i.e. 10mm – 75mm)
Coal dust (waste product of coal mining)
Industrial waste material as small grains or pelletised
- Tobacco industry (dust + stems + boiler ash)
- Sugar industry (bagasse)
- Oil production (press cake)
- Boiler ash
Bio matter grains or pelletised
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